Cellularcrete wall system

Abstract

A cellularcrete wall system (CWS) having a metal track, an aligner, a plurality fo wall tubes, and a lintel beam. The metal track is fastened to a floor. The plurality of wall tubes is fastened, at the bottom, to the metal track and guided, at the top, by the aligner. Each wall tube has tongue-and-grove ends for fastening each wall tube to another wall tube. Some wall tubes are filled with concrete for supporting a load and connecting foundation to lintel beam. The lintel beam is made from two AAC fiber-mesh boards on both sides as part of the lintel beam. The two AAC fiber-mesh boards are secured to the aligner and braced with metal rod and collar at a top of the lintel beam. Concrete is poured between the fiber-mesh boards of the lintel beam.

1 . A cellularcrete wall system comprising: 
 a metal track fastened to a floor;    an aligner;    a plurality of wall tubes fastened to the metal track and guided by the aligner, each wall tube including AAC reinforced with fiber mesh, with each wall tube having tongue-and-grove ends for fastening each wall tube to another wall tube, with a multiplicity of wall tubes filed with concrete for supporting a load; and    a lintel beam having two AAC fiber-mesh boards on both sides of the lintel beam as part of the lintel beam and secured to the aligner at a bottom and braced with metal rod and collar at a top of the lintel beam, with concrete poured between the AAC fiber-mesh boards of the lintel beam.    
   
   
       2 . The CWS as set forth in  claim 1 , with the fiber mesh including any of alkaline-resistant fiberglass, rust-proof coated steel fiber, nylon fiber, or other fibers.  
   
   
       3 . The CWS as set forth in  claim 1 , with the fiber mesh including any of single layer or multilayer mesh.  
   
   
       4 . The CWS as set forth in  claim 1 , further including vertical steel reinforcements for interconnecting the wall floor to the lintel beam.  
   
   
       5 . The CWS as set forth in  claim 1 , with the aligner for providing stiffness of the plurality of wall tubes, for covering the wall tubes where no vertical steel reinforcement and poured concrete are required, for adding strength to the lintel beam, and for guiding the plurality of wall tubes and lintel beam panels to a proper position prior to pouring concrete.  
   
   
       6 . The CWS as set forth in  claim 1 , with the aligner for guiding the plurality of wall tubes and lintel beam panels to a proper position prior to pouring concrete.  
   
   
       7 . The CWS as set forth in  claim 1 , with the aligner for adding strength to the lintel beam.  
   
   
       8 . The CWS as set forth in  claim 1 , further including: 
 two stiffeners placed vertically to cover the plurality of wall tubes and the two AAC fiber-mesh boards;    an angle fastened to the floor; and    a brace diagonally connected to the angle on the floor and the two stiffeners, for adjusting true plumb of the plurality of wall tubes.    
   
   
       9 . The CWS as set forth in  claim 1 , with adjacent wall tubes in the plurality of wall tubes glued to each other.  
   
   
       10 . A method for making a CWS, comprising the steps of: 
 fastening a metal track to a floor;    fastening a plurality of wall tubes to the metal track and guided by an aligner, each wall tube including AAC reinforced with fiber mesh, with each wall tube having tongue-and-grove ends;    fastening each wall tube to another wall tube in the plurality of wall tubes;    filling a plurality of wall tubes with concrete for supporting a load and connecting a foundation to a lintel beam;    securing, as part of the lintel beam bean, two AAC fiber-mesh boards on both sides of the lintel beam;    securing the two ACC fiber-mesh boards to the aligner at a botom;    bracing-with metal rod and collar at a top of the lintel beam; and    pouring concrete between the AAC fiber-mesh boards of the lintel beam and vertical tube cell wherever required.    
   
   
       11 . The method for making a CWS, as set forth in  claim 10 , with the step of fastening the plurality of wall tubes to the metal track including the step of fastening the plurality of wall tubes to the metal track with each wall tube including AAC concrete reinforced with fiber mesh, with the fiber mesh including any of alkaline-resistant fiberglass, rust-proof coated steel fiber, nylon fiber, or other fibers.  
   
   
       12 . The method for making a CWS, as set forth in  claim 10 , with the step of fastening the plurality of wall tubes to the metal track including the step of fastening the plurality of wall tubes to the metal track with each wall tube including AAC concrete reinforced with fiber mesh, with the fiber mesh including any of single layer or multilayer mesh.  
   
   
       13 . The method for making a CWS, as set forth in  claim 10 , further including the step of interconnecting with vertical steel reinforcements the wall floor to the lintel beam.  
   
   
       14 . The method for making a CWS, as set forth in  claim 10 , further including the steps of: 
 providing, with the aligner, stiffness of the plurality of wall tubes;    covering, with the aligner, the wall tubes where no vertical steel reinforcement and poured concrete are required;    adding, with the aligner, strength to the lintel beam; and    guiding, with the aligner, the plurality of wall tubes and lintel beam panels to a proper position prior to pouring concrete.    
   
   
       15 . The method for making a CWS, as set forth in  claim 10 , further including the step of providing, with the aligner, stiffness of the plurality of wall tubes.  
   
   
       16 . The method for making a CWS, as set forth in  claim 10 , further including the step of covering, with the aligner, the wall tubes where no vertical steel reinforcement and poured concrete are required.  
   
   
       17 . The method for making a CWS, as set forth in  claim 10 , further including the step of adding, with the aligner, strength to the lintel beam.  
   
   
       18 . The method for making a CWS, as set forth in  claim 10 , further including the step of guiding, with the aligner, the plurality of wall tubes and lintel beam panels to a proper position prior to pouring concrete.  
   
   
       19 . The method for making a CWS, as set forth in  claim 10 , further including the steps of: 
 placing two stiffeners vertically to cover the plurality of wall tubes and the two AAC fiber-mesh boards;    fastening an angle to the floor;    connecting a brace diagonally to the angle and the two stiffeners; and    adjusting, with the brace, true plumb of the plurality of wall tubes.    
   
   
       20 . The method for making a CWS, as set forth in  claim 10 , further including the step of gluing adjacent wall tubes in the plurality of wall tubes-to each other.  
   
   
       21 . The CWS as set forth in  claim 1 , with the Cellularcrete uses normal or high strength concrete.  
   
   
       22 . The cellularcrete wall system as set forth in  claim 1 , with the plurality of wall tubes having a thickness ranging from 4 inches to 24 inches, and with the cell thickness of the plurality of wall tubes ranging from ¾ inch to 4 inches.  
   
   
       23 . The wall tubes and lintel boards for CWS as set forth in  claim 1  can be manufactured by formed and poured or by the method of extrusion and cured at room temperature or autoclaved.